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Doosan DX225LL Excavator Log loader Shop Manual K1045081E-1 – PDF DOWNLOAD
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Doosan DX225LL Excavator Log loader Shop Manual K1045081E-1 – PDF DOWNLOAD
Serial Number 5001 thru 5017
K1045081E-1
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Doosan DX225LL Excavator Log loader Shop Manual K1045081E-1 – PDF DOWNLOAD
DESCRIPTION:
Doosan DX225LL Excavator Log loader Shop Manual K1045081E-1 – PDF DOWNLOAD
Serial Number 5001 thru 5017
K1045081E-1
GENERAL SAFETY ESSENTIALS
- Accessory Applications The forest machine has been primarily designed for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN for proper installation and application.
- Lifting-work applications (unless restricted or prohibited by local regulations) are permitted in approved lift configuration, to rated capacity only, with no side-loading. DO NOT use the machine for activities for which it was not intended.
- DO NOT use the bucket for lifting work, unless lift slings are used in the approved configuration. Use of an accessory hydraulic hammer (breaker), work in rough terrain, demolition applications or other hazardous operation may require installation of additional protective structures to safeguard the operator.
Lifting Capacity Rating Configuration
- Lifting capacity ratings that are printed at the end of this safety section are based on the machine being level, on a firm supporting surface, with hooks and slings attached in approved configuration. Loads must be balanced and supported evenly.
- Use tag lines to keep the load steady if wind conditions and large surface area are a problem. Work crew hand signals, individual tasks and safe procedures should all be universally understood before the lift is made.
TABLE OF CONTENTS:
Doosan DX225LL Excavator Log loader Shop Manual K1045081E-1 – PDF DOWNLOAD
Table of Contents.............................................................................. 7 Safety......................................................................................... 9 Track Forest Machine Safety SP001655....................................................... 11 Safety Precautions..................................................................... 15 Applicable Models...................................................................... 15 To the Operator of a DOOSAN Forest Machine............................................. 16 Learn the Signal Words Used with the Safety Alert Symbol........................... 18 General Safety Essentials.............................................................. 20 Accessory Applications............................................................. 20 Lifting Capacity Rating Configuration.............................................. 20 Location of Safety Labels.............................................................. 21 Summary of Safety Precautions for Lifting in Digging Mode.............................. 22 Unauthorized Modifications............................................................. 23 General Hazard Information............................................................. 23 Safety Rules....................................................................... 23 Safety Features.................................................................... 23 Inside Operator's Compartment...................................................... 24 Clothing and Personal Protective Items............................................. 24 Breathing Masks, Ear Protection May Be Required.................................... 25 Vibration Level Information........................................................ 25 Recommendations for Limiting Vibrations............................................ 25 Mounting and Dismounting........................................................... 26 Fuel, Oil and Hydraulic Fluid Fire Hazards......................................... 27 Precautions When Handling Fluids at High Temperature............................... 27 Asbestos Dust Hazard Prevention.................................................... 28 Injury from Work Equipment......................................................... 28 Fire Extinguisher and First Aid Kit................................................ 28 Protection from Falling or Flying Objects.......................................... 29 Attachment Precautions............................................................. 30 Accumulator........................................................................ 30 Indoor Ventilation................................................................. 31 Emergency Exit..................................................................... 31 Before Starting Engine................................................................. 32 Work Site Precautions.............................................................. 32 Checks Before Starting Engine...................................................... 33 Engine Starting.................................................................... 34 Before Operating Machine........................................................... 34 Machine Operation...................................................................... 36 When Swinging or Changing Direction of Travel...................................... 36 Travel Precautions................................................................. 37 Traveling on Slopes................................................................ 38 Prohibited Operations.............................................................. 38 Precautions for Operation.......................................................... 39 Avoid High Voltage Cables.......................................................... 40 Operate Carefully on Snow, Ice and in Very Cold Temperatures....................... 40 Operations on Slopes............................................................... 41 Parking Machine.................................................................... 41 Never Let Anyone Ride on Attachment................................................ 41 Maintenance............................................................................ 42 Warning Tag........................................................................ 42 Clean Before Inspection or Maintenance............................................. 42 Proper Tools....................................................................... 43 Use of Lighting.................................................................... 43 Fire Prevention and Explosion Prevention........................................... 43 Burn Prevention.................................................................... 44 Welding Repairs.................................................................... 44 Warning for Counterweight and Front Attachment Removal............................. 46 Precautions for Removal, Installation, and Storage of Attachments.................. 46 Precautions When Working on Machine................................................ 47 Lock Inspection Covers............................................................. 47 Crushing Prevention and Cutting Prevention......................................... 48 Track Tension Adjustments Require Caution.......................................... 48 Supports and Blocking for Work Equipment........................................... 48 Action When Abnormality Is Found During Inspection................................. 49 Precautions with High-pressure Lines, Tubes and Hoses.............................. 49 Waste Materials.................................................................... 50 Hydraulic Cylinders, Pins and Bushings............................................. 50 Battery................................................................................ 51 Battery Hazard Prevention.......................................................... 51 Boost Starting or Charging Engine Batteries........................................ 52 Towing................................................................................. 53 Precautions When Towing............................................................ 53 Shipping and Transportation............................................................ 54 Obey State and Local Over-the-Road Regulations..................................... 54 Lifting With Sling..................................................................... 54 Specifications................................................................................. 55 Specification for DX225LL SP001656......................................................... 57 Safety Precautions..................................................................... 61 Applicable Models...................................................................... 61 General Description.................................................................... 63 Component Locations.................................................................... 64 General Dimensions..................................................................... 66 Working Range.......................................................................... 68 General Specifications................................................................. 69 Engine Performance Curves (Per DIN6270 Standard)...................................... 70 Approximate Weight of Workload Materials............................................... 72 Performance Tests...................................................................... 74 Log Loader Performance Standards....................................................... 75 Test Conditions.................................................................... 75 Travel Speed and Travel Motor Balance (Steering Deviation) Tests................... 75 Swing Speed and Deceleration Force Test............................................ 77 Cylinder Performance Tests......................................................... 79 General Maintenance............................................................................ 81 General Maintenance Procedures SP000016.................................................... 83 Safety Precautions..................................................................... 87 Applicable Models...................................................................... 87 Welding Precautions and Guidelines..................................................... 88 Hydraulic System General Precautions................................................. 90 Maintenance Service and Repair Procedure............................................... 91 General Precautions................................................................ 91 Hydraulic System Cleanliness and Oil Leaks............................................. 92 Maintenance Precautions for Hydraulic System Service............................... 92 Oil Leakage Precautions............................................................ 93 Cleaning and Inspection................................................................ 94 General Guidelines................................................................. 94 Bearing Inspection................................................................. 95 Standard Torques SP000813..................................................................103 Safety Precautions.....................................................................107 Applicable Models......................................................................107 Torque Values for Standard Metric Fasteners............................................108 Torque Values for Standard U.S. Fasteners..............................................109 Type 8 Phosphate Coated Hardware.......................................................111 Torque Values for Hose Clamps..........................................................112 Torque Values for Split Flanges........................................................112 Torque Wrench Extension Tools..........................................................113 Torque Multiplication..............................................................113 Other Uses for Torque Wrench Extension Tools.......................................114 Tightening Torque Specifications (Metric)..........................................115 Upper Structure................................................................................119 Cabin SP000943.............................................................................121 Safety Precautions.....................................................................125 Applicable Models......................................................................125 Removal................................................................................126 Installation...........................................................................130 Counterweight SP001657.....................................................................133 Safety Precautions.....................................................................137 Applicable Models......................................................................137 General................................................................................138 Warning for Counterweight and Front Attachment Removal.............................138 Removal................................................................................140 Installation...........................................................................141 Fuel Tank SP001658.........................................................................143 Safety Precautions.....................................................................147 Applicable Models......................................................................147 General Description....................................................................148 Parts List.........................................................................148 Specifications.....................................................................149 Specifications.....................................................................151 Removal................................................................................152 Installation...........................................................................157 Start-up Procedures....................................................................160 Fuel Transfer Pump SP000021................................................................161 Safety Precautions.....................................................................165 Applicable Models......................................................................165 General Description....................................................................166 Theory of Operation................................................................166 Troubleshooting........................................................................167 Replacement of Rotor and Vane..........................................................167 Replacement of Rear Cover..............................................................168 Replacement of Armature................................................................168 Swing Bearing SP001777.....................................................................169 Safety Precautions.....................................................................173 Applicable Models......................................................................173 Swing Bearing Maintenance..............................................................174 Operating Recommendation...........................................................174 Measuring Swing Bearing Axial Play.................................................174 Measuring Bearing Lateral Play.....................................................174 Swing Bearing Basic Operation......................................................175 Rebuilding Swing Bearing...........................................................175 Swing Reduction Gear SP001659..............................................................177 Safety Precautions.....................................................................181 Applicable Models......................................................................181 General Description....................................................................183 Theory of Operation................................................................183 Parts List.........................................................................184 Specifications.....................................................................185 Troubleshooting, Testing and Adjustment................................................186 Removal................................................................................187 Disassembly............................................................................188 Cleaning and Inspection (Wear Limits and Tolerances)...................................197 Reassembly.............................................................................198 Shaft and S/R Bearing Heatfit.....................................................198 Assembly of Carrier Subassemblies..................................................198 Assembly of Main Case..............................................................204 Assembly of Motor..................................................................220 Installation...........................................................................224 Startup Procedures....................................................................225 Lower Structure andChassis.....................................................................227 Track Assembly SP001660....................................................................229 Safety Precautions.....................................................................233 Applicable Models......................................................................233 General Description....................................................................234 Track Tension..........................................................................234 Cleaning and Inspection (Wear Limits and Tolerances)...................................237 Track Shoe.........................................................................238 Lower Roller.......................................................................240 Upper Roller.......................................................................241 Front Idler........................................................................242 Track Shoes and Links..................................................................243 Track Removal......................................................................243 Track Installation.................................................................244 Front Idler Roller.....................................................................246 Parts List.........................................................................246 Front Idler Roller Disassembly.....................................................247 Front Idler Roller Reassembly......................................................248 Lower & Upper Roller...................................................................250 Parts List.........................................................................250 Lower & Upper Roller Removal.......................................................251 Lower & Upper Roller Disassembly...................................................251 Lower & Upper Roller Reassembly....................................................252 Lower & Upper Roller Installation..................................................253 Track Spring and Track Adjusting Cylinder..............................................254 Parts List.........................................................................254 Engine and Drive Train.........................................................................257 Drive Coupling (Main Pump) SP000026........................................................259 Safety Precautions.....................................................................263 Applicable Models......................................................................263 Drive Coupling.........................................................................264 Installation of Drive Coupling.........................................................265 Installation Procedure.............................................................265 Hydraulics.....................................................................................267 Hydraulic System Troubleshooting, Testing and Adjustment SP001661..........................269 Safety Precautions.....................................................................273 Applicable Models......................................................................273 Hydraulic System - General Notes.......................................................274 Hydraulic Schematic....................................................................275 General Notes......................................................................275 Operation of Working Components........................................................277 Boom Operating Circuit.............................................................277 Boom Up Circuit....................................................................277 Boom Down Circuit..................................................................277 Arm Operating Circuit..............................................................278 Arm Crowd Circuit..................................................................278 Arm Dump Circuit...................................................................278 Bucket Operating Circuit...........................................................279 Bucket Crowd Circuit...............................................................279 Bucket Dump Circuit................................................................279 Swing Operating Circuit............................................................279 Right Swing Operating Circuit......................................................280 Left Swing Operating Circuit.......................................................280 Swing Relief Valve and Makeup Valve................................................280 Travel Operating Circuit...........................................................280 Forward Travel Circuit.............................................................281 Reverse Travel Circuit.............................................................281 Procedural Troubleshooting Baseline Recommendations....................................282 Initial Checks and Tests to Establish Operating Condition of the Forest Machine....282 Pilot Pressure.........................................................................284 Adjustment and Testing.............................................................284 Power Mode Valve.......................................................................285 Current Signal and Hydraulic Pressure Adjustments..................................285 Swing Priority Valve...................................................................286 Control Valve Pressure and Current Adjustments.....................................286 Pressure Up Valve......................................................................288 Checks and Adjustments.............................................................288 Pump Input Power Control...............................................................290 Pump Regulator Adjustment..........................................................290 Flow Meter and Flow Meter Kit Installation and Testing.................................294 Swing System Troubleshooting...........................................................296 Precautions/Initial Checks.........................................................296 Swing Relief Valve Checking and Adjustment.........................................297 Troubleshooting – Swing Gearbox........................................................299 Troubleshooting – Hydraulic Problems...................................................300 Troubleshooting – Control Valve........................................................302 Troubleshooting – Travel Control Valve.................................................303 Troubleshooting – Joystick Control Valve...............................................304 Accumulator SP000028.......................................................................305 Safety Precautions.....................................................................309 Applicable Models......................................................................309 General Description....................................................................310 Specifications.....................................................................312 Center Joint (Swivel) SP001778.............................................................313 Safety Precautions.....................................................................317 Applicable Models......................................................................317 General Description....................................................................318 Parts List.........................................................................319 Troubleshooting, Testing and Adjustment................................................320 Inspection.........................................................................320 Testing............................................................................320 Disassembly............................................................................321 Reassembly.............................................................................322 Cylinders SP001666.........................................................................323 Safety Precautions.....................................................................327 Applicable Models......................................................................327 General Description....................................................................328 Theory of Operation................................................................328 Parts List.........................................................................330 Special Tools and Materials............................................................332 Piston Nut.........................................................................332 Piston Jig.........................................................................334 Steel Bushing Jig..................................................................336 Dust Wiper Jig.....................................................................338 Slipper Seal Jig...................................................................340 Slipper Seal Straightening Jig.....................................................342 Disassembly............................................................................344 Reassembly.............................................................................349 Swing Motor SP000194.......................................................................353 Safety Precautions.....................................................................357 Applicable Models......................................................................357 Operation Manual.......................................................................359 Information on Marking.............................................................359 Specifications.....................................................................360 Structure and Operational Principles...............................................361 Cautions...........................................................................368 Maintenance Instructions...............................................................375 Disassembly and Assembly...........................................................375 Maintenance........................................................................387 Travel Motor SP000253......................................................................389 Safety Precautions.....................................................................393 Applicable Models......................................................................393 General Description....................................................................394 Theory of Operation................................................................395 Parts List.........................................................................403 Specifications.....................................................................407 Special Tools and Materials............................................................408 Hydraulic Motor Part...............................................................408 Reduction Gear Part................................................................409 Tightening Torque Chart............................................................410 Troubleshooting, Testing and Adjustment................................................411 General Precautions................................................................411 Troubleshooting....................................................................411 Disassembly............................................................................415 General Caution Matters............................................................415 Reduction Gear Part................................................................415 Hydraulic Motor Part...............................................................421 Cleaning and Inspection (Wear Limits and Tolerances)...................................426 Maintenance Standard...............................................................426 Reassembly.............................................................................429 General Caution Matters............................................................429 Hydraulic Motor Part...............................................................429 Checkup after Assembly.............................................................445 Performance Test...................................................................445 Installation...........................................................................447 Check..............................................................................447 Piping.............................................................................447 Gear Oil...........................................................................447 Oil Filling........................................................................448 General Caution Matters............................................................448 Main Control Valve SP000034................................................................449 Safety Precautions.....................................................................453 Applicable Models......................................................................453 General Description....................................................................455 Theory of Operation................................................................455 Parts List.........................................................................484 Specifications.....................................................................489 Troubleshooting, Testing and Adjustment................................................490 Troubleshooting....................................................................490 Adjustment of Valves...............................................................491 Disassembly............................................................................493 Cleaning and Inspection (Wear Limits and Tolerances)...................................503 Cleaning...........................................................................503 Inspection.........................................................................503 Reassembly.............................................................................504 Caution on Assembly................................................................504 Sequence of Subassembly............................................................505 Maintenance of Relief Valves.......................................................511 Installation...........................................................................514 Start-up Procedures....................................................................514 Main Pump & PTO SP000988...................................................................515 Safety Precautions.....................................................................519 Applicable Models......................................................................519 Section................................................................................521 General Repair Guidelines..............................................................522 Seal Kits and Sub- assemblies..........................................................523 Disassembly............................................................................527 Sealing the Drive Shaft............................................................527 Gear Pump Sealing..................................................................529 Control Housing....................................................................530 Control Module LR..................................................................533 Control Module H...................................................................534 Controller.........................................................................535 Rotary Groups......................................................................537 Intermediate Wheel.................................................................540 Auxiliary Drive....................................................................542 Inspection Hints.......................................................................545 Assembly...............................................................................550 Rotary Group.......................................................................550 Pump...............................................................................551 Hydraulic Component - Measurement "D"..............................................554 Control Housing....................................................................557 Intermediate Wheel.................................................................560 Gear Pump..........................................................................561 Cover / Auxiliary Drive............................................................562 Assembly Guidelines for Tightening Torques.............................................563 Bolts (to N 08.001)................................................................563 Plugs with Internal Hexagon and Profile Seal Ring (to N 02.009)....................564 Seal-Lock - Sealing Nuts (to N 02.100).............................................564 Axial Piston Pump SP000068.................................................................565 Safety Precautions.....................................................................569 Applicable Models......................................................................569 Axial Piston Pump......................................................................570 General Description................................................................570 Special Tools and Materials........................................................575 Troubleshooting, Testing and Adjustment............................................577 Disassembly........................................................................579 Cleaning and Inspection (Wear Limits and Tolerances)...............................582 Reassembly.........................................................................584 Start-up Procedures................................................................588 Regulator for Axial Piston Pump........................................................589 General Description................................................................589 Special Tools and Materials........................................................600 Troubleshooting, Testing and Adjustment............................................600 Preparation for Disassembly........................................................603 Regulator Disassembly..............................................................603 Regulator Reassembly...............................................................606 Remote Control Valve (Work Lever / Joystick) SP000069......................................609 Safety Precautions.....................................................................613 Applicable Models......................................................................613 General Description....................................................................615 Theory of Operation................................................................615 Parts List.........................................................................616 Specifications.....................................................................618 Torques............................................................................618 Tools and Materials....................................................................618 Disassembly............................................................................619 Cleaning and Inspection (Wear Limits and Tolerances)...................................623 Reassembly.............................................................................623 Start-up Procedures....................................................................629 Travel Control Valve (with Damper) SP000070................................................631 Safety Precautions.....................................................................635 Applicable Models......................................................................635 General Description....................................................................637 Theory of Operation................................................................637 Deceleration Valve.................................................................638 Dampening Parts of the Control Section.............................................639 Causes of Faults and Measures..........................................................641 Parts List.........................................................................642 Specifications.....................................................................643 Torques............................................................................643 Removal................................................................................644 Disassembly............................................................................645 Cleaning and Inspection (Wear Limits and Tolerances)...................................648 Assembly...............................................................................649 Installation...........................................................................655 Startup Procedures....................................................................656 Solenoid Valve Assembly SP000445...........................................................657 Safety Precautions.....................................................................661 Applicable Models......................................................................661 Parts List.............................................................................662 Functions of 5-Solenoid Valve Assembly Package.........................................663 Functions of Solenoid Valve Assembly Package.......................................663 Assembly Diagram and Tools Required................................................665 Solenoid Valve Diagram.............................................................667 Check Points and Solutions for Problems............................................668 Hydraulic Schematic (DX225LL) SP001662.....................................................671 Safety Precautions.....................................................................675 Applicable Models......................................................................675 DX225ll................................................................................677 Electrical System..............................................................................679 Air Conditioner SP001775...................................................................681 Safety Precautions.....................................................................685 Applicable Models......................................................................685 Air Conditioner System.................................................................686 Outline............................................................................686 Internal and External Filters......................................................687 Air-Conditioning System Layout.....................................................689 Air Conditioner/Heater Circuit Diagram.............................................690 Air Conditioner/Heater Unit........................................................691 Relay - Blower.....................................................................695 Relay - A/C........................................................................695 Duct Sensor........................................................................695 Water Temp Sensor..................................................................696 Internal Air Temp Sensor...........................................................696 Ambient Air Temperature Sensor.....................................................696 Sun Sensor.........................................................................697 Control Panel......................................................................697 Compressor.........................................................................705 Receiver Dryer.....................................................................705 Troubleshooting........................................................................706 Weight of R134a Gas Used In Machines...................................................708 Refrigerant System Repairs.............................................................709 Refrigerant Safe Handling Procedures...............................................709 Repair and Replacement Procedure...................................................710 Refrigerant Recovery...............................................................712 Vacuuming Refrigerant System.......................................................712 Leakage Check......................................................................714 Refrigerant Charging...............................................................714 Inspecting System For Leakage......................................................716 Electrical System SP000958.................................................................717 Safety Precautions.....................................................................723 Applicable Models......................................................................723 Introduction...........................................................................725 Electrical Supply System...............................................................726 Engine Starting Circuit................................................................728 Start Operation....................................................................728 After Start........................................................................730 Engine Preheating System...............................................................732 Engine Stop............................................................................734 Charging System........................................................................736 Monitoring System......................................................................737 Instrument Panel...................................................................738 Monitoring System Schematic........................................................740 Operation..............................................................................742 Instruments........................................................................742 Warning and Indicator Lights...........................................................744 Indication of Warning Lights.......................................................744 Indication of Multifunction Gauge and Letter Information Area......................745 Initial Operation......................................................................747 Mode Selector Switch...................................................................747 Graphic Information Area Display.......................................................748 Overview...........................................................................748 Main Menus for the Graphic Display Area............................................749 Menu Selector Buttons..............................................................749 Main Menu..............................................................................750 Language...........................................................................750 Set Clock..........................................................................751 Filter/Oil Info....................................................................751 Adjust Display.....................................................................752 Set Password.......................................................................753 Special Menu...........................................................................754 Entering/Accessing and Exiting/Escaping Menus......................................754 Special Menu Selections............................................................755 Electronic Hydraulic Control System (eEPOS)...........................................772 Control System Schematic...........................................................772 Power Mode Control.....................................................................774 Operation..........................................................................776 Power Mode Control Circuit Diagram...................................................778 Work Mode Control......................................................................780 Operation..........................................................................781 Work Mode Control Circuit Diagram....................................................782 Engine Control System..................................................................783 Engine Control Dial....................................................................784 Engine Control Circuit Diagram.........................................................785 Automatic Deceleration Control (Auto Idle Control).....................................786 Engine Overheat Protection System......................................................788 Power Boost Mode.......................................................................790 Operation..........................................................................790 Power Boost Control Circuit Diagram..............................................792 Automatic Travel Speed Control.........................................................794 Automatic Travel Speed Control Circuit Diagram...................................796 Selfdiagnostic Function...............................................................797 eEPOS Controller..................................................................797 Wiper System...........................................................................799 Wiper Circuit......................................................................799 Wiper operation....................................................................800 Lighting System........................................................................802 Lighting System Circuit Diagram....................................................802 Kind of Light......................................................................803 Operation..........................................................................803 Audio Controller.......................................................................804 Audio Controller Circuit Diagram...................................................804 Electrical Schematic (DX225LL) SP001663....................................................805 Safety Precautions.....................................................................809 Applicable Models......................................................................809 DX225ll................................................................................811 Attachments....................................................................................813 Boom and Arm SP001664......................................................................815 Safety Precautions.....................................................................819 Applicable Models......................................................................819 Front Attachment Pin Specifications....................................................820 DX225LL............................................................................821 Size and Weight Specifications.....................................................821 Front Attachment - Removal and Installation............................................822 Arm Removal Procedure..............................................................822 Boom Removal Procedure.............................................................824 Installation...........................................................................825 Arm Installation Procedure.........................................................825 Boom Installation Procedure........................................................825 Start-up Procedures....................................................................825 Boom and Arm(Forest MachineFront Option) SP001665..........................................827 Safety Precautions.....................................................................831 Applicable Models......................................................................831 Front Attachment Pin Specifications....................................................832 DX225LC/DX225LL....................................................................833 Front Attachment - Removal and Installation............................................834 Arm Removal Procedure..............................................................835 Boom Removal Procedure.............................................................837 Installation...........................................................................838 Arm Installation Procedure.........................................................838 Boom Installation Procedure........................................................838 Start-up Procedures....................................................................838 Bucket (Forest Machine Front Option) SP001779..............................................839 Safety Precautions.....................................................................843 Applicable Models......................................................................843 Bucket Tooth Inspection and Replacement................................................844 Bucket O-ring Replacement..............................................................845 Bucket Shimming Procedures.............................................................847 New Bucket Installation............................................................847 Bucket Attachment, Removal and Reversal................................................849 Detaching the Bucket...............................................................849 Attaching the Bucket...............................................................849 Reversing the Bucket...............................................................850
DOOSAN DX225LL EXCAVATOR LOG LOADER SHOP MANUAL K1045081E-1 – PDF DOWNLOAD:
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